Filson: Custom Sand Control Screen Manufacturer
After strictly control the production process of sand control screen, Filson enables to provide high performance products in line with the standards of ISO and API.
- Fully customized to fulfill well applications
- Superb resistance to corrosion and abrasion
- Easy and fast to install with precision packing
- Low tendency to clogging for large open area
- Robust construction with precision dimensions
- Cost-effective solution with superior performance
What is Sand Control Screen
As a crucial sector in exploiting oil, natural gas and water underground, Filson sand control screen acts as a separator to prevent sand particles in. Compared to downhole desanders, it has more precision dimensions and higher efficiency at removing particles.
Generally speaking, Filson sand control screen is formed by top-grade metal materials, such as stainless steel, titanium, mild steel and other alloys, which all demonstrate well in resistance erosion, better mechanical strength and low maintain costs.
Available in multiple design and types, Filson sand control screen exhibits specialized sand-proof property without plugging in harsh conditions, which greatly improves well productivity. We also provide relate products like premium screens, well screen, perforated pipe screen, etc.
Sand Control Screen Types
Filson wedge wire screen is also called wire-wrapped screens (WWS). Its biggest feature is a triangle shape, which is arranged in a parallel way. Feature in well-welded structure, clogging resistance, and a larger circulation area, it is designed to retain substance and filtration.
Available in a broad range of filtration media like glass beads, gravel sand, Filson gravel pack screen, also known as prepacked well screen, is featured with excellent sand retention capacity, precision accuracy, and unbeatable collapse strength, which greatly reduces the drilling process.
Using advanced punching technology, Filson bridge slotted screen has accurate slot openings, superior mechanical strength and excellent water entering capacity, which provides free flow and optimal sand control. Hence, it greatly prolongs the service life of water wells.
With excellent wellbore support and better sand control capacity, Filson expandable sand screen is able to improve well productivity even in unconsolidated and weak environments. It uses expandable screens for sand control, which really reduces operation costs by up to 25%.
With superb strength, compressive resistance, and impact, Filson perforated casing is widely used as a supporting part for sand control systems in drilling oil or water wells. With uniform slots, it allows liquids to flow smoothly. Adding preservative treatment to improve corrosion resistance.
Sand Control Screen Types by Materials (3)
- Filson carbon steel well screen delivers better mechanical strength with higher collapse strength compared to stainless steel well screen. Thanks to superb sand retention capacity with less costs, it can perfect protect your well equipment and maximizes well productivity.
Sand Control Screen Types by Applications (2)
- Expect the standard materials of stainless steel, Filson water well sand screen also supports other materials such as PVC, galvanized steel, etc. This allows our product to eliminate complex sand control problems, with customized service, it can meet almost prevailing water well conditions.
- Filson sand screen in oil well is widely regarded as sand control well screen. Due to all-welded construction and top-grade materials, it is endowed with sufficient strength and excellent resistance to corrosion and collapse. Besides, it can also effectively prevent sand pumping.
Sand Control Screen Benefits
Consecutive slot openings and enable Filson sand control screen to have wider available open area, which increases well yield and prolongs operational time of the well.
To ensure the highest solids retention, Filson sand control screen is equipped with precision sand size control, uniform filter slots and a larger circulation area.
Every Filson sand control screen adopts optimized and special construction designs, such as keystone slot of slotted liner, which allows smoothly and freely flow without plugging.
Formed by top-grade and highly abrasive mental materials, Filson sand control screen is endowed with strong resistance to corrosion and temperature properties to adapt any harsh condition.
Advantages of Sand Control Screen
Provides following advantages, Filson sand control screen is poplar solution for your well applications.
- Durability: With stable and rigid construction, and after stringent quality control, Filson sand control screen can easily response to the complex well conditions with little abrasion. Due to the superior performance of our product, it also greatly prolong the durability of wells.
- Professional: Utilizing international advanced welding and laser cutting technology, Filson sand control screen achieves smooth surface, larger containment capacity, uniform gap and strong mechanical strength, which ensures better performance in quality and efficiency.
- Multiple Size: Filson is able to make sand control screen with wide ranged based on the holes and the sizes of sand particles of your applications, which can prevent the erosion of surface equipment, casing and tubing caused by plugging.
Sand Control Screen Specific Features
With smooth performance and superior quality, Filson sand control screen can response to any sand control challenge.
- Lower costs for longer service life and backwash capability
- Multiple series to suit various well and drilling applications
- Well-welded and sturdy construction with light weight
- Less possibility of clogging due to special slot design
- Quick delivery ensured by Fedex/TNT/DHL available
- Best balance between oil production and sand control
- Greatly save rig time compared to other sand control system
- Positive and quality compliance well support
- Multiple connecting types ensure convenient handle
- Superior sand retention capacity without clogging or plugging
- Wider open area allows water or oil flow freely and smoothly
- OEM service to offer customized shapes, sizes or materials
- Reliable quality in accordance with ISO, AOI certifications
Why Choose Filson Sand Control Screen
Filson sand control screen, also known as sand screen, is featured with uniform and compact slots, which lower the risks of clogging and greatly improve oil recovery quality and productivity. Hence, it becomes a popular choice in unconsolidated formations, heavy oil wells, etc.
As a professional manufacturer, Filson will recommend the best sand control screen for your applications based on the sand particles sizes and the flow. Because too small pore will cause clog early and need remedial workover while too big pore will erode tube.
Having more than two decades years experiences, Filson is constantly developing new advanced technologies to produce high performance sand control screen for customers, in order to maximize the value of customers applications.
Buy our product or you can contact us, we will provide technical support and design assistance for you, including screen size recommendations, installation methods, analysis of sand in formation and well of oil and water construction consultation.
Filson technical staff like sales, design team, technical support are here for you at any time, please feel free to give us a call at +86-157 3695 8886 or send us an email at firstname.lastname@example.org.
The general specifications of sand control screen as following, you can choose from them or send us your special requirement.
- Raw Material: stainless steel 304, 316L, nickel, Monel, high carbon steel, or other alloys
- Screen OD: 44 mm – 181 mm
- Base pipe OD: 15 mm – 140 mm
- Screen ID: 10 mm – 127 mm
- Slot opening: 150 micron – 300 micron
- Slot style: straight slot, keystone slot
- Tensile strength: 390 Mpa
- Thickness: 3 – 10 mm
- Depth: up to 1000 ft.
- Style: single layer or multiple layers
- End connection: welded collar, thread, flanges
- Certification: API, ISO
- Pipe type: slotted, perforated
- Oil and gas applications
- High-rate water well screens
- Cased-hole and open hole stand-alone screens
- Vertical, deviated, and horizontal wells
- Geothermal systems
- Recharge wells
- Aquifer storage and recovery wells
- Irrigation systems
- Stand-alone completions
- Gravel-pack and frac-pack completions
- Long and extreme-reservoir-contact wells
- Pump strainer screens
- Traditional sand screens
- Domestic water well sand screens
- Industrial filter
- Wells with severe downhole conditions
- Sandface sensor installations
This guide covers all the vital aspects of sand control screen such as components, features, material type, design and size, just to mention a few.
So, before importing sand control screen, read this guide.
It will help you become an expert in sand control screen.
What is a Sand Control Screen?
A sand control screen is a device that you use to prevent impurities such asrocks and sand from getting into the wellbore.
What is the function of a Sand Control Screen?
Sand control screens are a must for applications involving oil, water, gas, steam production, or any other production activity that is located deep underground.
Sand can be produced either as a result of dragging force resulting from injection fluid or dragging force.
Similarly, mechanical failure close to the wellbore is also a common cause of sand production.
Installing sand control screens will help you mitigate the negative impacts of sand and the potential harm it can cause to your system.
You should insert sand control screens on bores drilled deep below the surface to capture sand particles and excepting only very fine particles.
It acts as a separator that removes sand from the process fluid.
Consequently, installing a sand control screen will help you with:
- Reducing machinery impairment as a result of sand plugging
- Protecting surface facilities such as separators, pumps, piping from erosion and damage
- Eliminating risks of downhole cavities
- Reduced cost of cleanup, sand disposal, and maintenance
- Eliminating sand bridging problems
What types of Sand Control Screens are there?
You can choose from a wide selection of the available sand control screens available.
Choose a sand control screen after doing a proper analysis of formation sand for a specific wellbore.
You can also custom engineer a sand control screen to match the specificity of individual wellbore conditions.
The most common types of sand control screens include:
i. Standalone Screen
These types of screens will initially allow fine silt and sand to pass through.
After a while, the sand packs form around the screen enabling it to act like filtration media, preventing the entry of fine and coarse sand into the wellbore.
Some types of standalone screens include:
ii. Slotted Liner
It is the most common and oldest type of sand control screens.
It is also the simplest and the cheapest.
It constitutes a series of slots axially cut through a wall of a tubular cylinder.
These slots width are designed to form inter-particles bridging across the slots.
These types of screens have an average flow area between 3% and 6% of the total pipe area.
However, a higher flow area has detrimental effects on the tensile strength of the pipe.
You can select between straight and keystone slots.
The straight slots are more economical and have a higher resistance to wear and tear but also have a higher probability of clogging compared to keystone.
Keystone slots can self-flush and hence a better choice compared to the straight slot.
In essence, the shape ensures that all the sand grains that get into the hole completely go through the wall.
Keystone slots have increased work efficiency and a lower probability of clogging hence more expensive than straightslots slotted liners.
Generally, the slots can be customized between 0.012 to 0.250 inches in width and 1.5 to 2.5 inches in length to suit the special needs of the customer.
iii. Wire-Wrapped Screens
This type of sand control screen constitutes a wire wrapped jacket welded around a perforated pipe.
There are three main types of wire-wrapped perforated screens including:
- Pipe-bases direct build screen
- Pipe-based slip-on and
- Rod-based screens
Ideally, it is constructed through helically wrapping a keystone wire around the vertical ribs and welding every point of contact.
The design helps reduce sand plugging the screen, flow friction, and supports self-cleaning.
Wire wrapped screens havea larger flow area, better slot opening, and strength compared to slotted liners.
You must have a well-sorted formation with these types of screens for maximum production and performance.
iv. Pre-packed Screens
This type of sand control screen resembles a wire wrapped screen though the filtering media is different.
It constitutes a perforated base pipe, support rib, gravel pack, inner, and outer screen jackets.
It is a modified wire wrapped screen used in standalone or well-sorted sand completions where conventional gravel packing is not economical or feasible.
The packed gravels help stabilize the borehole while filtering sand from the process fluid excepting only very fine particles.
It is best suited for maximum production and sand removal.
Where there is a concern of plugging with drilling mud and completion fluid, you can use Carbiliteproppant in place of re-sieved gravel.
Carbolite offers more precise grain size sorting, larger pore throats, and higher permeability compared to standard re-sieved gravels.
v. Metal Mesh Sand Screen
These screens can be either single or multiple layered sintered laminate.
They offer a wide range of opening ratings varying from 40 to 1000 microns.
You can select from a wide range of materials including stainless steel, Monel, Inconel, etc. and has to be keenly considered to improve on the wellbore performance.
The main advantages of a metal mesh screen include:
- Reduced pressure drop
- Higher flow area
- High strength and degree of flexibility
- Reusable and
- Controlled pore sizes
vi. Wedge Wire Screens
This device is commonly used in oil, water, and gas industries.
The structure wires forming V shape profiles that are welded to a support rib.
It comes with greater slot tolerance and superior strength.
It has no clogging and offers higher production due to continuous slot placement.
They have a high open area, very low-pressure drop, uniform, and precise slot spacing.
vii. Premium Screens
These screens are all-metal designs with metal mesh filtration and outer metal shroud.
These screens have a higher ability to resist plugging and backflow of drilling fluid through the screens.
You can customize the premium screens to meet your specific desires with a pore ranging between 60 to 300 microns.
Initially, the screens will only capture large sand particles which build up to form a filtration cake which proceeds and capture both large and fine particles.
viii. Expandable sand Control Screens
These types of screens constitute a filter media, base pipe, integral expandable connector, and outer protection shroud.
With these types of screens, you have to run them into a wellbore then place the expansion insert to expand them to fit the production hole.
Consequently, they offer more effective sand control because of the maximum hole diameter, increase in flow area, and wellbore support.
ix. Gravel Pack and Frack Packs
Gravel pack uses filter media made from sized sand to prevent sand production.
There are two types of gravel packs, that is, case hole and open hole gravel packs.
Frack packs screens combine both the gravel packs and fracturing techniques to create long and wide conductive fractures.
The technique improves productivity as well as suitably controls sand production in the wellbore.
What are the Components of a Sand Control Screen?
The components of sand control screens vary from one type of sand control screen to the other.
The simplest sand control screen, the slot liner only has a base pipe and the slots.
Some like the wire wrapped pre-packed sand screen have a perforated base pipe, gravel packs, support rib, and inner and outer screens.
What types of Applications use Sand Control Screen?
You can use sand control screens in diverse types of applications that involve drilling deep below the surface.
Some of the applications which require sand control screens include:
- Gas-sand separators
- Conventional sand screens
- Pump strainer screens
- Gravel and frack packaging
- Industrial filters
- Extreme-reserve and long contact wells
- Sand face sensor installations
- Standalone completions
- High rate screens in water wells
- Screens for domestic water wells
- SAGD horizontal sand screening
- Horizontal, vertical and deviated completions in injector wells, oil and gas industries
What are the Features of a Good Sand Control Screen?
A good sand control screen should possess the following qualities:
- Should have a more open area
- Capable of being produced in customized design
- Uniform and precisely placed slots
- Precision slot opening
- Resist plugging
- Reduced pressure drop
- Minimal energy usage by energy and drawdown
- Great mechanical and tensile strength
- Easy to install
- Large open area
- Increased flexibility
- Robust support shroud
- Uniform pore/slot sizes
- Stable over a wide range of temperature and pressure
Why should you use a Sand Control Screen?
When you drill into underground oil, water, or gas reservoir, you produce fluids that are contaminated with several impurities.
You need to remove these impurities at the drilling point to avoid transferring them to the refining facility.
Unfortunately, rarely do these facilities have the capability of removing the heavy-duty contaminants.
When the contaminants reach builds up in the machinery and equipment, you will suffer heavy economic losses as a result of downtime, revenue loss, cleanup, and repair.
The whole wellbore can also get capped resulting in loss of millions of dollars.
What Types of Materials are Suitable for Constructing Sand Control Screens?
The choice of a specific material will depend on the special conditions of a specific wellbore which is pre-determined from the geological analysis.
The material will also depend on the design and type of sand control screen you want to use.
Generally, you can use any of the following materials to construct a state of art sand control screen:
- Stainless steel 304, 304L,316, 316L, 904
- Alloy 825/625/C276
- High strength carbon steel
- Titanium etc.
What is Screen Bonding?
Screen bonding is constructing a sand control screen using multiple layers of woven wire mesh.
This helps in combining the filtration-specific needs of a more robust and specialty woven products.
A bonded sand screen has the following benefits:
- Fixed pore geometry to ensure effective sand control when the operating pressure is high
- Increased service since it has low porosity and low-pressure drop
- A monolithic structure for precise particle retention and superior mechanical characteristics.
- A broad micron rating for effective sand control over a wide spectrum of formation sand.
What Factors should you Consider when Selecting Sand Control Screens?
There are several types of sand control screen which vary in their suitability and superiority to specific conditions of wellbore applications at hand.
The secret to achieving the optimal performance of a sand control technique is to find a balance between sand retention and productivity impairment.
When selecting a sand control screen, you should consider the following factors:
- The micron rating of the screen/aperture size
- Permeability of the screen
- Particle size distribution
How can you test the efficiency of a Sand Control Screen?
You can test the effectiveness of a sand control screen through sand retention testing.
There are two sand retention tests that you can conduct.
· Slurry Test
The test simulates noncompliant wellbore conditions.
Consequently, you will suspend sand on a slurry and flow it through the screen.
Take the weights of particles produced through the screen.
Also, record the rate of pressure build-up across the screen against the quantity of sand contacting the screen
· Sand Pack Test
This test simulates a collapsed borehole or a compliant sand control.
Place sand directly on the screen then flows a wetting fluid through the screen and sand pack.
Weigh the quantity of sand going through against the pressure drop/pressure builds up across the screen.
What Factors Affect the Efficiency of the Sand Control Screen?
The performance of a sand screen depends on multiple factors including but not limited to:
- The screen permeability
- The reservoir particle size, distribution, and uniformity
- The type/design of the screen
- The fluid flow rate
- The pressure gradient
- Micron rating of the sand screen
- Sand formation conditions
- The size of flow and open areas
How can you Analyze the Properties of Sand Particles?
You can measure the particle size and particle size distribution using two methods: laser particle size analysis (LPSA) and dry sieving.
This method employs light diffraction to measure sand particle properties.
Using this method, you place your sample on a fully automated laser diffraction analysis unit and get your readings on the computer.
· Dry Sieving
The method relies on cleaning, crushing, drying, weighing, and sorting your samples using sieves conforming to requirements of ASTM E1170 standards.
You should record the weight of sand retained through successive sieving down to mesh size of 44 micrometers.
Consequently, you can determine the sand distribution plot by plotting the cumulative percentage weight for each sample against the sieve aperture on semi-log coordinates.
Can you Clean Sand Control Screens?
Yes, you can clean and reuse sand control screens.
Cleaning is done through dissolving sand, scales, and fines from plugged screens.
You can achieve this through pumping fluids using high-energy jetting tool coiled tubing for maximum penetration.
How Long can a Sand Control Screen last?
A good sand control screen should be durable.
The length of the service life of a sand screen significantly varies from one application to the other.
The type of sand screen, operating conditions, frequency of use, and maintenance also plays a very influential role in determining how long the sand screen will last.
Generally, a sand screen constructed using a strong material can take several years if it doesn’t get physically damaged through ‘hotspot’.
Some sand control screens like gravel packs can even last the entire life of the wellbore.
In some cases, the manufacturers recommend that you replace slotted liners, wire wrapped screens, and pre-packed screens every two years.
Gravel packed screens take longer and can be replaced every four years.
What is the Gravel Packing?
Gravel packing is a technique you can use to control production sand in a wellbore.
The aim is to maintain well productivity through a stabilized formation.
Through proper design, this type of sand control screen can provide sufficient sand control throughout the service life of the wellbore.
In this type of operation, you first place a steel screen inside the well then pack it with gravel of standard size to help prevent the passage of sand.
You have to determine the median grain size and the grain size distribution of the formation sand to come up with the most appropriate size of gravel pack sand.
How can you Design and Size a Sand Control Screen?
The first step you have to do is collect reservoir sand and analyze it for grain size distribution, particle size, grain consolidation, range of grain sizes, and uniformity.
You can do the analysis using a laser particle size analysis technique.
You should consider the following factors when designing your sand screen control:
- The type of sand screen control
- Strength of construction material
- Adequate size
- The flow rate and size of the well
- The inflow capacity
- Screen permeability
- The micron rating or the size of the screen aperture
How do you Maintain a Sand Control Screen?
You should schedule regular wellbore surveillance to enable you to detect any signs of screen erosion.
Also, you should increase the wellbore test frequencies upon any signs of increasing sand concentrations and/or flow velocities.
You can also establish an intelligent well system (IWS) to enable you to conduct multi-rate tests on specific zones to detect any changes in completion pressure.
This will let you know whether your screens have lost their integrity.
You should also conduct sand screen cleaning, chemical sand treatment, through-tubing screen or patching, and through-tubing gravel pack as appropriate.
How much can a Sand Control Screen cost?
The cost of owning a sand screen control varies to the type, design, and size of the screen selected.
Slotted liners are the cheapest and cost approximately $ 300 followed by wire wrapped and prepacked screens at $ 800 and $ 1200 respectively.
The gravel packed is the most expensive and can cost about $8000 to replace.
You should also include manpower, rig time, and workover operations costs.
FilSon offers competitive prices on all sand control equipment.
With our high-quality material, and robust construction, FilSon sand control screen offers exceptional performance.
Contact us now for the best prices on sand control screen.